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Vauxhall Workshop Service and Repair Manuals

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Engine maintenance using a section engine > < Replace (right) engine damping block

Astra H

Manual Transmission, Remove from Engine and Install

  Remove

1.   Remove engine
2.   Detach refrigerant line connection (1) from compressor
•   Unscrew bolt
Object Number: 2412701 Size: DEFAULT


3.   Disconnect wiring harness plug (1) from compressor
Object Number: 2412702 Size: DEFAULT


4.   Detach cooling module from front axle body
•   Remove coolant hose (2) from thermostat housing
– Release clamp
•   Detach charge air hose (1) from throttle valve body
– Release clamp
•   Detach charge air hose (3) from intercooler
– Release clamp
•   Detach coolant hose (4) from coolant port
– Release clamp
•   Take off cooling module
Object Number: 2412703 Size: DEFAULT


5.   Detach heat shield, start-up catalytic converter
•   Unscrew 3x bolts (1)
Object Number: 2412704 Size: DEFAULT


6.   Detach start-up catalytic converter
•   Detach from turbocharger
– Unscrew 4x bolts (1)
•   Detach from bracket for start-up catalytic converter
– Unscrew 2x bolts (2)
Object Number: 2412705 Size: DEFAULT


7.   Detach bracket, start-up catalytic converter (1)
•   Unscrew 2x bolts
Object Number: 2412706 Size: DEFAULT


8.   Place collecting basin underneath.
9.   Remove intermediate shaft (1) with right hand axle shaft (2)
•   Detach intermediate shaft bracket
– Unscrew 2x bolts (3)
•   Pull intermediate shaft with axle shaft out of differential
•   Seal opening in differential with sealing plug
Object Number: 3446582 Size: DEFAULT


10.   Remove left-hand axle body
•   Remove axle shaft with KM-313 and KM-6003-1 from differential gear
•   Seal opening in differential with sealing plug
Object Number: 2417912 Size: DEFAULT


11.   Remove engine from front axle body
•   Attach retaining ropes KM-2356
– Attach to engine transport shackles
•   Attach to workshop crane
•   Remove front engine damping block
– Unscrew screw connection (1)
•   Remove rear engine damping block
– Unscrew screw connection (2)
Object Number: 2417913 Size: DEFAULT


12.   Lift engine with gearbox from front axle body
Note:   2 people
13.   Attach KM-412-34 (1)
•   Tighten 3x bolts
Object Number: 2412708 Size: DEFAULT


14.   Attach KM-412-11-1 (1)
•   Tighten 3x bolts
Object Number: 2412709 Size: DEFAULT


15.   Install engine on engine overhaul stand KM-412-A
Note:   2 people
•   Tighten 8x bolted connections
•   Detach retaining ropes KM-2356 from engine transport shackles
16.   Disconnect wiring harness plug (1) from the reversing light switch
Object Number: 3446583 Size: DEFAULT


17.   Unscrew gearbox (2)
•   Attach manual transmission with KM-2358 (1) to workshop crane with ropes
•   Unscrew 10x bolt
Note:   Note different bolt lengths
Object Number: 2405493 Size: DEFAULT


18.   Remove gearbox
•   Unscrew bolt
•   Remove gearbox from engine flange
Note:   Ensure that attached parts and wiring harnesses are undamaged

  Install

19.   Install gearbox
•   Attach gearbox to engine flange
•   Install bolt
•   Unhitch workshop crane
•   Remove holding ropes
20.   Bolt gearbox tightly
•   Attach transmission to cylinder block
– Tighten 7x bolt 60 Nm
•   Attach transmission to oil pan
– Tighten 4x bolt 40 Nm
21.   Hitch engine up to workshop crane.
•   Attach retaining ropes KM-2356
– Attach to engine transport shackles
•   Attach to workshop crane
22.   Detach engine from engine overhaul stand KM-412-A
Note:   2 people
•   Detach 8x bolted connections
•   Raise engine carefully
23.   Remove KM-412-34
•   Unscrew 3 bolts
24.   Remove KM-412-11-1
•   Unscrew 3 bolts
25.   Fit engine to front axle body
Note:   2 people
•   Carefully lower onto front axle body
•   Remove retaining ropes KM-2356
– Detach from engine transport shackles
•   Detach from workshop crane
26.   Fit rear engine damping block
•   Tighten new screw connection 55 Nm
27.   Fit front engine damping block
•   Tighten new screw connection 55 Nm
28.   Install left-hand axle body
•   Attach new circlip (1) to axle body
•   Lubricate teeth and bearing points with engine oil
•   Push axle body into gearbox until circlip engages
29.   Install intermediate shaft with right hand axle shaft
•   Attach new retainer
•   Lubricate teeth and bearing points with engine oil
•   Push intermediate shaft into gearbox until retainer engages
•   Attach intermediate shaft bracket
– Tighten 2x bolt 18 Nm
Object Number: 2417920 Size: DEFAULT


30.   Attach bracket, start-up catalytic converter
•   Tighten 2x bolts
31.   Attach start-up catalytic converter
•   Attach to turbocharger
– Replace gasket
– Tighten 4x bolt 26.5 Nm
Note:   Note different bolt lengths
•   Attach to start-up catalytic converter bracket
– Tighten 2x bolts
32.   Attach heat shield, start-up catalytic converter
•   Tighten 3x bolt 11.7 Nm
33.   Attach cooling module
•   Insert into lower radiator bracket
•   Attach coolant hose to coolant port
– Fasten clamp
•   Attach refrigerant line to compressor
– Replace gaskets
– Tighten bolt 22 Nm
•   Connect compressor wiring harness plug
•   Attach charge air hose to intercooler
– Fasten clamp 3.5 Nm
•   Attach charge air hose to throttle valve body
– Fasten clamp 3.5 Nm
•   Attach coolant hose to thermostat housing.
– Fasten clamp
34.   Attach refrigerant line connection to compressor
•   Replace 2x seal rings
•   Tighten bolt 20 Nm
35.   Install engine

Engine maintenance using a section engine > < Replace (right) engine damping block